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Vietnam Japan Gas JOINT STOCK COMPANY

Project Name: LONG SON METERING STATION & UNDERGROUND PIPING

Package: PIPING, CIVIL, E&I DESIGN PACKAGE

Location: LONG SON – BA RIA VUNG TAU PROVINCE

CONSTRUCTION MoS FOR Checked by Approved by

VJG
UNDERGROUND PIPING

Checked by Approved by

IEV

A 15-July-19 Design Manager Approved by


Rev. Date Description Prepared by Checked by JPS
Main contractor: Document No.:
IDEMITSU ENGINEERING
VIETNAM CO., LTD (IEV) 190009-02-PP-MOS-029
Sub-contractor:
PHUC SANG MINH GAS
ENGINEERING CO., LTD (JPS)

Initial Date
QA Check
No. 190009-02-PP-MoS-029
IDEMITSU ENGINEERING VIETNAM CO., LTD.
Page: 2/18
Issued on 15th July 2019
For VIETNAM JAPAN GAS JSC
LONG SON METERING STATION & U/G PIPING

TABLE OF CONTENTS

Project number and name ............................................................................. 4

Project Address ............................................................................................. 4

Codes & Standards ....................................................................................... 4

Technical Specifications / Documents ........................................................... 5

General ......................................................................................................... 6

Manpower and Equipment. ........................................................................... 6

General flow chart ......................................................................................... 8

Material control.............................................................................................. 9

Handling and Transportation ......................................................................... 9

Excavation..................................................................................................... 9

Wrapping ..................................................................................................... 10

String out the pipes into trench.................................................................... 10

Welding ....................................................................................................... 11

NDE ............................................................................................................ 11

Repair of welding ........................................................................................ 11

Backfilling .................................................................................................... 11

Pressure test line. ....................................................................................... 11

Holiday detection checks shall be carried out and recorded. ...................... 12

Drawings ..................................................................................................... 12

IDEMITSU ENGINEERING VIETNAM CO., LTD.


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LONG SON METERING STATION & U/G PIPING

Preparation for testing ................................................................................. 12

Test pack preparation and control ............................................................... 12

All final inspection and documentation after pressure testing shall be done in
accordance with method statement for pressure test of piping. ............................. 12

Records of pressure test and leak test shall include the following items. .... 13

Repairing of defects .................................................................................... 13

Inspection and testing ................................................................................. 13

Attached document ..................................................................................... 18

Reference document ................................................................................... 18

IDEMITSU ENGINEERING VIETNAM CO., LTD.


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LONG SON METERING STATION & U/G PIPING
Applicability
This method statement shall be applied to the LONG SON METERING STATION & U/G
PIPING PJ.
This method statement covers the excavation, installation, jointing and backfilling of
underground coated carbon steel piping.
Pressure testing of all piping systems will be conducted in accordance with Hydrostatic Test
Procedure
- This method statement is to be read in conjunction with the site-specific safety
induction and the current site procedures in operation, to ensure:
- Works are carried out in a safe manner at all times.
- The hazards related to the activity are understood.
- Avoid all exposure to injury, ill heath, damage or accidents.

Project information

Project number and name


- Project number: 190009.
- Project name: LONG SON METERING STATION & U/G PIPING PJ

Project Address
Long Son – Ba Ria Vung Tau province.

Applicable codes and standards

Codes & Standards


The work standards and code of practice shall be used as reference and formed the basic
guideline for installation. They are as follows:
(1) AB4510_K2000_0: Reference Erection Manual
(2) ASME B 31.3 Chapter V Fabrication, Assembly and Erection
(3) ASME B 31.3 Chapter VI Examination, Inspection and Testing ASME BPVC Sec. II
Part C Welding Rods, Electrodes and Filler Metals ASME BPVC Sec. V
Nondestructive Examination
(4) ASME BPVC Sec. IX Welding and Blazing Qualifications
(5) The Government applicable Laws, Regulations and applicable Standards shall be at
the latest versions.
(6) VJG, IEV Safety Standard.

IDEMITSU ENGINEERING VIETNAM CO., LTD.


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LONG SON METERING STATION & U/G PIPING

Technical Specifications / Documents


The following technical specification / documents shall be used in conjunction with this
document
190009-02-GE-QC-003 Project Quality Plan
190009-02-PP-SP-007 Painting specification/ procedure
190009-02-PP-SP-008 Specification for pipeline
190009-02-PP-SP-012 Welding procedure specification
190009-02-PP-SP-027 Anti corrosion and field joint coating specification
Note : If there are any conflicting requirements between this specification and individual
specification or drawings, the requirement shall be governed in accordance with the
following order.
(1) Drawing and individual specifications
(2) This specification
(3) Codes and standards

Roles & responsibilites

(1) Project Manager


Project Manager shall responsible for overall management and HSE of all Construction
activities at site including installation and testing of underground piping.
(2) Piping Manager
Piping Manager shall be responsible for overall management of piping activities.
He shall be responsible for implementation of this procedure and shall pass the instruction
down the line to maintain the required quality level.
(3) Piping Engineer
Piping Engineers shall be responsible for planning and executing installation activities of
underground piping at site and implementation of quality and HSE plans during construction.
(4) Piping Supervisor
Piping Supervisors shall be responsible for requisitioning the materials required for
installation, ensuring the installation as per approved drawings and implementation of good
piping work and HSE work practices in their areas of operation.
(5) Civil Manager
Civil construction manager is responsible for the excavation and back filling of piping
trenches, construction of concrete pits and all associated survey work.

IDEMITSU ENGINEERING VIETNAM CO., LTD.


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LONG SON METERING STATION & U/G PIPING

(6) QA/QC Manager


QA/QC Manager shall be responsible for overall management of QA/QC activities.
He shall be responsible for non conformance management quality audits both internal and
external.
(7) QC Engineer
QC Engineers shall be responsible for QA/QC activities, material control and traceability,
and review of test packages for hydro tests.
He shall also be responsible for non conformance management and internal quality audits.
(8) QC Inspector
QC Inspectors shall be responsible for carrying out inspection activities and witnessing NDE
during the installation processes and coordinating with the owner’s QA/QC personnel for
inspection and certification, as per approved ITP.
(9) Safety Officer
Safety officer shall be responsible for coordination with HSE authorities of owner safety
officer shall monitor all the works to ensure that they are carried out correctly and in safe
manner and advise supervisors for corrective measure, if required.
He shall ensure that toolbox talks are held which shall cover details of specific tasks to the
personnel and specific job risks involved are explained to the work force involved.

Working procedure

General
- When welder is welding, he shall wear the appropriate safety equipment and clothing
to prevent him from getting an electric shock or burns.
- A confined space entry permit is required before entry to confined space.
- When welding in confined space, an extractor must be installed to remove hazardous/
toxic fumes and to ventilate the area, if necessary a mask shall be worn and an assistant
will be posted at the entrance to the work area in case of emergency.
- When welding, inflammable materials must be removed from work area to avoid
causing a fire.
Manpower and Equipment.
- Tools & machine list shall be approved and obtained the stamp by VJG & IEV checking
stamp before accessing to site.
- All persons shall join Safety training before working at VJG site.

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LONG SON METERING STATION & U/G PIPING

Tools & Machine List

No Description Unit Q'ty Remarks


1 GPS positioner No. 1

2 Laser machine No. 1

3 Measure tape No. 1

4 Excavator 0.5m3 No. 1

5 Concrete mixer No. 1


6 Cranes 50 tons No. 1
7 Crane truck No. 1

8 Heavy trailer truck No. 4


9 Chain block 5 tons No. 4

10 Generator No. 1
11 Welding machine No. 2
12 Holiday detector No. 01

13 Submersible pump 20m3/hr No. 02

14 Oxigen detector No. 4


15 Hand tool No. 1
16 Fire extinguisher Lot 1

- Materials motorized equipment & construction workers ready before the works.
 Manpower

Detail Unit Number Note


No

1 Supervisor Person 4
2 Leader Person 2
3 Worker Person 8~12

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LONG SON METERING STATION & U/G PIPING

General flow chart

1 Pipe transportation


2 Excavation


3 Wrapping (External)


4 Pin hole test & inspection


5 Internal cleaning and arrangement


6 Fit-up and welding at site


7 NDT welded joints


8 Wrapping welded joints


9 Holiday test


10 Pressure test

IDEMITSU ENGINEERING VIETNAM CO., LTD.


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LONG SON METERING STATION & U/G PIPING

11 Pig cleaning


12 Connect to valve holes


13 Flushing and purging


14 Backfilling and finishing

Material control
(1) Coated carbon steel pipe shall be provided by the contractor (IEV). All delivery
inspections and certifications are done by contractor (IEV). All pipes shall be inspected
for conformity by QC inspector.
(2) Welding consumables shall be controlled in accordance with Welding Material Control
Procedure.

Handling and Transportation


(1) All coated pipes will be handled by means of wide sling bands or belts to avoid
damaging the coating material.
(2) Coated pipe shall be handled with wide nonabrasive canvas, leather belts and or other.
(3) All equipment designed to prevent damage to the coating.
(4) The use of tongs, bare pinch bars, chain slings, rope slings without canvas or
composition belt slings with protruding rivets, pipe hooks without proper padding or
any other handing equipment found to be damaging to the coating shall not be
permitted.
(5) All skid used to support coated pipe shall be padded.
(6) Walking on the pipe shall not be permitted.

Excavation
(1) Excavation by machine shall be carrying out if the working space is within the safe limit
against the existing facilities.

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LONG SON METERING STATION & U/G PIPING

(2) Manual excavation shall be performed if the working area is to close to the existing
underground facilities.
(3) Shuttering or sheet piling (if required) should be done initially to ensure proper
protection and stability of the existing facilities before commencing the excavation
work.

Wrapping
(1) Details of procedure shall be in accordance with Anti corrosion and field joint coating
specification 190009-02-PP-SP-027.
(2) Inspection and Testing
All coating shall be subject to 100% visual inspection and 100% inspection with an
electrical holiday detector. The holiday detector shall be as per NACE RP-02-74 during
the inspection of the anti-corrosion tape coating. Holiday detector shall not be
permitted to remain stationary around coated pipeline with the operating voltage
switched on. All defects shall be clearly marked.
(3) Repairs to Coating
All the defects in coating should be fixed immediately after the detection.
Details of repair procedure shall be in accordance with Anti corrosion and field joint
coating specification

String out the pipes into trench


(1) Prior pipe string out, civil work for trench shall be completed.
(2) Pipe joints will be laid individually in the trench on sand bags, suitable spaced to support
the length of pipe being installed.
(3) On long pipe lengths, sand bags will be spaced on five meter centers.
(4) To avoid damage to coating and following accepted construction practices.
(5) Pipe will be installed in the trenches using wide sling belts and / or hands.
(6) Tolerance of pipe laying shall be as follows :
The level of the pipe at any point along its length is to within ±15mm of the level stated
on the drawings.
The center line of the pipe at any point along its length is to be within ±50mm of the
location stated on the drawings.

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LONG SON METERING STATION & U/G PIPING

(7) Pipe lowering into trench, pipe shall be inspected internally for dust / debris which, shall
be cleaned (air blowing, brushing etc…)

Welding
(1) Welding preparation, fit up, inspection and testing shall be carried out in accordance
with Specification for Piping Fabrication.
All surfaces to be welded shall be free from oxides, scale, oil or other foreign matter.
Production joints shall be made using qualified welding procedures and welders.
(2) Visual inspection shall be done by welding inspector during and after welding.
The daily welding report shall be generated by construction team in accordance with
Welding Control Procedure.

NDE

(1) Required NDE shall be requested and carried out in accordance with method statement
for NDE control. All NDE requests shall be transmitted to subcontractor by QA/QC
manager.
(2) Contractor will transmit hard copies of NDE information to the owner. Matrix operator
will input NDE date to the data base.

Repair of welding
Welding repair shall be carried out in accordance with method statement for Welding Control
Procedure.

Backfilling
(1) Backfilling work shall be carried out in accordance with Procedure for Earth Work.
(2) Pipe padding should go after pipe bedding by filling with suitable materials 300mm thick
from top of pipe.
(3) Subsequently after completing the pipe padding backfilling of suitable excavated earth
material shall be placed 300mm in layers and compacted in accordance with project
specification requirements.

Pressure test line.


(1) Epoxy coating shall be done at site.
(2) Pipe surface shall be prepared by mechanical power tool cleaning.
(3) Fit up and welding shall be carried out as per WPS.

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LONG SON METERING STATION & U/G PIPING

(4) Hydro test shall be carried out after completion of all NDE(if required) and spool
clearance activities.
(5) After completion of hydro test and its acceptance by owner, the epoxy coating of welded
joints shall be done.
(6) If any repair, modification occurs in the site during installation to the fabricated spool
then the same spool shall be recoated and re-hydro tested in the site with the above
same procedures.
(7) The epoxy coating application shall be done in accordance with manufacturer’s
instructions.

Holiday detection checks shall be carried out and recorded.

Drawings
As-built drawings must be drawn before leak test (As-built drawing shall be checked during
punch check).

Testing

Preparation for testing


(1) A punch list(will be attached in the Pressure test procedure) shall be prepared by
construction team to verify that the piping system are installed to the extent necessary
for testing.
(2) A test punch list shall be made through line check and punch list will be to verify that
all piping components requiring post test actions are documented.
(3) After all punch items are completed satisfactorily, both contractor and owner shall sign
all necessary documents.
(4) Pipe lines shall be thoroughly blown out by nitrogen.
(5) Lines shall be free from all debris such as trash, welding rods, rags, tools, etc.

Test pack preparation and control


(1) Preparation and control of test package shall be done in accordance with Pressure
Test Procedure
(2) All test package shall be approved by owner prior to the start of pressure testing.

All final inspection and documentation after pressure testing shall be done in accordance
with method statement for pressure test of piping.

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LONG SON METERING STATION & U/G PIPING

Records of pressure test and leak test shall include the following items.
(1) Date of test
(2) Identification of piping tested (line number and service)
(3) Test fluid
(4) Test pressure
(5) Certification by examiner
(6) Design pressure
(7) Photograph of pressure gauges and indication board showing the test sequence (time
and pressure, etc.)

Repairing of defects
(1) When the defective material found during construction, a repairing method and extent
shall be prepared.
(2) Imperfections in welds exceeding specified limitations shall be considered as defects,
removed and repaired in accordance with the followings.
(3) Defects shall be removed completely under the careful examination.
(4) Repair welding shall be also done in accordance with welding procedure specification
(WPS)
(5) Repaired welds shall be examined and inspected in accordance with Specification for
Piping Fabrication.

Inspection and testing


(1) All the work shall be inspected or examined as per approved ITP and inspection
records shall be prepared as per ITP.
(2) Before starting the job the drawings shall be checked for the latest revision.
(3) All piping material & welding consumables shall be checked for conformity to
specifications, construction drawings and approved WPS.
(4) All measuring instruments shall be checked for valid calibration.
(5) Area to be welded shall be checked for the cleanliness, free of paint, grease, dirt etc.
(6) Each piping installation, including it’s components and workmanship, shall be
examined to ensure compliance with applicable examination requirement

Safety

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LONG SON METERING STATION & U/G PIPING

(1) The unsafe work practices and conditions in the work place shall be immediately
identified and eliminated through the use of analytical techniques such as risk
assessment.
(2) Build a team safety mentality where each worker contributes to the effort and each
superintendent is fully aware of the capabilities and limitations of their team.
(3) All tools and equipments shall be used in accordance with the manufacturer’s
recommendations, required tool guards in place, and maintained in good working
order.
(4) Where appropriate shall require employees to wear eye, ear, head and face, foot
protection outfit.
(5) Special care shall be taken for the erection of scaffolding and ladders at height.

Safety Point and Countermeasure

Sequence of Task Potential Hazards Recommendations / Control Measures

►All works to be fully supervised at all times.


►If the supervisor has to leave the area, for any
reason, then the job will be temporarily
Mark out exact suspended until such time he returns to site.
Minor works only, no
location of proposed ►The excavation areas are to be identified on
major hazards
excavation site, plus attached plot plan, highlighting the areas which
associated with this
erection of barricades can be excavated using machinery and the
task.
and safety signs. critical areas which must only be excavated by
hand dig only.
Obtain excavation
certificate ►Hot work permit to be issued by AOFP safety
For information only.
including a hot work department.
permit
►Physical barricades shall be erected to prevent
access by unauthorized personnel.
►Warning signs to be erected also to advise
Contact with moving
personnel of ongoing excavation work.
machinery.
►Take all necessary precaution as required in
confined space procedure when working in
Heat source from diesel
excavation or trench 1.5m or above.
powered equipment is a
►All excavated area should be barricaded by safety
potential for explosion in barrier and alerted by warning light at night.
the event of gas escape
►Proper slope should be maintained in all trench

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LONG SON METERING STATION & U/G PIPING
Carry out excavation from live plant excavations (45deg slope is required or as per
work using 360° actual soil condition).
mechanical Earth sliding, cave-ins and ►Ladders, steps, ramps or other suitable means of
excavator and hand collapse. access and aggress shall be provided as per
digging operations as procedure.
per attached plan. ►Excavator operator and other related personals
should be properly trained.
►All rigging area should be properly barricaded by
suitable means.
►All riggers should be trained.
►Know the weight and C.G of the material to be
lifted and use proper tools and equipments.

Tear of slings / belts Fall of ►All rigging tools and tackles should be checked
Pipe laying in the before using.
materials
trench and fit-up
►No one should stand beneath the load.
►Do not allow unauthorized persons in rigging
premises.
►Ensure well maintained and periodic inspection of
equipment & tools’
►Only trained personnel is required to handle the
pressure testing equipment / tools.
►Ensure equipment is pre-mobbed and certified for
Equipment Failure
use
►Prior to testing, ensure proper check on hose
Bursting, Leakage of connections, blind points, bolting and on-line
test medium piping components and certified for test
►Ensure barriers / warning signs are in place around
Damage to ear drum test areas and specify distance.
Pressure testing
►Ear muffs must be worn at test area all time

Heat stress and dehydration ►Ensure weather condition is conducive for work.
►Ensure availability of potable drinking water at
work site and short break for workers.
►Wearing of PPE shall be mandatory in all aspects
of welding and cutting works.
►This shall include face shield and welding goggles.
►Hot work permit shall be secured prior to start of
any welding and cutting works.
►Fire extinguishers shall be available near the work
site at any time.
►Proper use of fire extinguishers shall be

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disseminated to all personnel involve in the job.
►All welding, grinding and cutting equipment shall be
inspected prior to start.
►This shall also include inspection of electrical
sources and cables.
►Damage cables shall be immediately replaced.
►Only properly trained personnel shall be permitted
to do welding and cutting works.
►Work area shall be properly barricaded.
►STAART required prior to start of task.
►Always check areas around and below prior to
commencing welding or cutting operations.
►Ali combustible materials under or near welding or
Welding and Cutting Fire, explosion, damage to burning operations must be moved to a safe
works lives and properties distance away or covered with a fire retardant
material.
►Welding leads and gas hoses shall not be placed
where they will present tripping hazards.
►Proper spark containment method such as fire
blanket shall be used when doing welding and
cutting.
►The welding machine shall be properly grounded
and as close to the work as possible.
►Never leave a welding rod in the electric holder
when not in use.
►Never use a torch as hammer to remove slag or
scale. Use the proper tool.
►Never use lighters, matches or cigarettes to light a
torch. Use only approved spark lighter.
►Welding machine shall be turned off at the end of
the shift.
►Fire Blanket shall be used for welding habitat.
►All galvanized pipe shall be cleaned in areas to be
welded prior to welding.
►Only skilled worker can carry out the job.
►Avoid water contact and keep grinding machine
Injuries by grinding
always dry.
machine
►Continuous training and remained hazard of
Grinding work grinding
Fire burn and eye injuries
►Damage of electric wire to be checked

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continuously.
►Grinding machine and grinding wheel should be
checked before use
►Wear adequate PPE
►Working area should protected by installing
warning tape and x-ray hazard symbol.
►Only skilled worker can carry out the job
NDE Exposure to X-ray ►Wear radioactive absorption batch when working to
neutralized radioactive emission.
►Proper housekeeping to be maintained at all times
►Material should never obstruct walkways /
staircase / ladders and access to emergency
Housekeeping and
equipments.
area cleaning Slip, Trip, Fall
►Area to be cleaned and barricades and warning
tapes to be removed
►Hose and fittings of gas cylinders shall be checked
for leak by
soapy water.
►Oxygen and fuel gas cylinders in storage shall be
separated by a minimum of 6 meters.
►Gas cylinders shall be handled carefully. Avoid
bumping or dropping them.
►Always secure in an upright position and properly
supported.
►Valve protection caps shall be on cylinders when
not in use and when being transported.
►Be sure protective caps are adequately screwed
Handling of down.
pressurize tanks Fire explosion damage lives ►Use a holding cage when lifting cylinders with a
(Oxygen, Acetylene, and properties crane.
Argon) ►Choking around cylinder shall not be allowed.
►Smoking is not allowed on the project site except in
properly designated areas.
►Discard butts approved containers, not on the
floor/ground or in trash cans.

►Every day before start of work tool box meeting to


be between
supervisor and worker.

All risks to be happened ►Supervisor should give information regarding

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during working hazards indulged to daily work activities.

General ►Always keep clean working area.


Expected risks during night ►Close supervision shall be done during late night
shift hours.
►Supervisor should give information regarding
hazards indulged to daily night work activities.
►Adequate drinking water facilities should be
provided.
►Every night before start of work tool box meeting to
be between supervisor and worker
Comments
1. JSA should be used in conducting Tool Box Talks(TBT) with all concerned workers
2. Provide that all the necessary PPE are used, relevant PTW requirements are followed and all the
control measures stated above are adhered to, the activity can proceed.

PPE & Safety Equipment Required to Perform Task (Tick as Appropriate)

Safety Hand Safety


Face Shield Goggle Barricade Harness
Helmet Gloves Shoes

Safety Fire
Ear Plug Coverall Work Permit Dust Mask Others
Glasses Extinguisher

Attachment

Attached document
No. Form no. Descriptions Remarks
Inspection and Testing Coat of Joint &
1 Attachment 01
Repairs
2 Attachment 02 Holiday Detector Test Report (HTR)

Reference document
No. Form no. Descriptions Remarks
1 190009-02-GE-QC-003 Project Quality Plan
2 190009-02-PP-SP-007 Painting specification/ procedure
3 190009-02-PP-SP-008 Specification for pipeline
4 190009-02-PP-SP-012 Welding procedure specification
Anti corrosion and field joint coating
5 190009-02-PP-SP-027
specification

IDEMITSU ENGINEERING VIETNAM CO., LTD.

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